Replace hard chrome with high-performance thermal spray coatings

A future-ready solution for durability, compliance, and cost efficiency

Across industries, hard chrome plating has long been used to protect critical components. However, tightening regulations, rising operational risks and new technical requirements increasingly challenge its viability. Thermal spray coatings, especially our carbide solutions, are a proven and well established alternative delivering higher performance and regulatory compliance. Oerlikon Metco offers the industry’s most advanced portfolio of thermal spray materials and technologies to replace hard chrome plating reliably, efficiently and at scale.

Explore key topics

What are the limitations of hard chrome?
Why choose thermal spray coatings?
What are the performance advantages of thermal spray over hard chrome?
In which industries is thermal spray used?

What are the limitations of hard chrome?

Performance and operational limitations

Hard chrome plating can struggle in demanding environments. Micro-cracking, limited corrosion resistance and reduced performance under cyclic or shock loading can restrict component lifetime and reliability.

Modern applications require more durable, consistent and long-lasting surface protection – requirements that hard chrome increasingly fails to meet.

Health, safety and environmental considerations

Hard chrome processes require complex infrastructure, including wastewater treatment, exhaust systems and continuous monitoring. Strict safety measures are necessary to manage exposure to Chromium(VI), adding operational complexity and cost.

Regulatory and business uncertainty

Chromium(VI) is classified as a Substance of Very High Concern (SVHC) under EU REACH. Increasing regulatory scrutiny, approval requirements and potential trade restrictions create uncertainty for long-term production planning.

Components treated with Chromium(VI) may also face import or export constraints or future trade restrictions. At the same time, volatile raw material markets—such as recent extreme tungsten price fluctuations – highlight additional supply chain and cost risks associated with traditional hard chrome processes. These challenges are driving the transition to alternative surface technologies that offer both higher performance and greater process security.

Why choose thermal spray coatings?

Thermal spray coatings as a superior alternative to hard chrome plating

When evaluating surface protection technologies, most customers look for reliable performance, regulatory certainty, and long‑term cost efficiency. Hard chrome plating struggles to meet these expectations due to Chrom(VI) restrictions, micro‑cracking, and wear limitations.

Thermal spray coatings offer a modern, sustainable and technically superior solution—helping companies reduce operational risk while improving component lifetime and performance.

Key benefits of choosing thermal spray

Outstanding wear resistance
HVOF carbide coatings deliver dramatically higher wear performance, enabling components to run longer with fewer failures.
High corrosion protection
Depending on the coating system, thermal spray coatings can exceed 1000+ hours in salt spray tests—far beyond typical hard chrome capabilities.
Improved fatigue behavior
Thermal spray builds denser, crack‑resistant coatings with lower residual stress, improving fatigue life by 12.5–17.9% compared to hard chrome.
Exceptional impact toughness
Coatings such as WC‑CoCr offer 7–8× higher impact resistance, performing reliably in demanding and shock‑loaded environments.
Higher hardness & lower volume loss
With superior hardness and proven results in ASTM wear testing (e.g., Miller Test), thermal spray coatings show significantly lower wear rates.
Environmentally and regulatory compliant
Thermal spray is 100% Chrom(VI)‑free, eliminating the need for REACH authorizations, complex permits, or hazardous waste handling.
Flexible and reconditionable
Surfaces can be rebuilt, repaired or upgraded—extending component lifetimes and reducing replacement costs.
Customizable to your application
With different material families (WC‑CoCr, Cr₃C₂‑NiCr, Flash Carbide, and more), coatings can be optimized for corrosion, wear, high‑temperature operation or fatigue strength.

What are the performance advantages of thermal spray over hard chrome?

Thermal spray coatings offer a modern, high‑performance and future‑proof replacement for hard chrome plating. Based on internal testing, they deliver superior wear, longer corrosion protection, better fatigue performance and significantly higher impact toughness.

Being fully Chrom(VI)-free, they also support compliance with current and upcoming regulations while providing a safer, more reliable and more sustainable coating solution.

Comparison of thermal spray and hard chrome plating

Key performance differences based on internal testing and application experience


Property	Hard chrome plating	Thermal spray (HVOF WC/CrC, Cr₃C₂‑NiCr, Flash Carbide)
Corrosion resistance	Often fails before 144 h in salt spray tests	Depending on system: 400–1000+ h
Wear resistance	Moderate	Up to 4× higher abrasion resistance
Fatigue resistance	Micro‑cracking; higher residual stress	Improved fatigue life by 12.5–17.9%; fewer micro‑cracks, lower stress
Impact toughness	Low	7–8× higher impact toughness; more durable in shock environments
Hardness & wear rate	Limited hardness; higher wear	Higher hardness and lower volume loss in ASTM G75 by ~78% reduction in volume loss versus HC
Environmental impact	Contains Chrom(VI); requires heavy safety systems	Chrom(VI)-free, no hazardous electrolytes or carcinogens
Repairability	Limited	Reconditionable and rebuildable
Regulatory compliance	Increasingly difficult	Fully compliant and future‑proof

In which industries is thermal spray used?

Thermal spray coatings are already widely used as proven replacements for hard chrome plating across several industries. Depending on the component requirements, materials such as WC‑CoCr, Cr₃C₂‑NiCr, WC/CrC in Ni‑Cu, or Flash Carbide offer superior wear, corrosion and fatigue performance. Below is an overview of typical applications where thermal spray provides a reliable and high‑performance alternative.

Examples of hard chrome replacement applications

Aerospace
Landing gears: Flash coatings or WC‑CoCr
Turbine components: Cr₃C₂‑NiCr
Steel industry
Furnace / guide rolls: Cr₃C₂‑NiCr
Process rolls: WC‑Co / WC‑CoCr
Paper & textile
Calender rolls: WC‑Co / WC‑CoCr
Printing / guide rolls: WC‑CoCr
Textile rolls: WC‑CoCr
Offshore, marine & mining
Offshore hydraulic rods: Cr₃C₂‑NiCr
Shafts, rotors, pump shafts: WC‑CoCr
Pump shafts, rotors, drill string components: WC/CrC in Ni‑Cu
Hydraulic cylinders / piston rods: Cr₃C₂‑NiCr, Flash coatings or WC‑CoCr
General engineering
Bearing and sealing surfaces: WC‑CoCr
Valve stems / valves: Cr₃C₂‑NiCr
Battery manufacturing
Calender rolls: WC‑Co / WC‑CoCr

Evaluate your hard chrome replacement strategy with our experts

Selecting the right coating solution can significantly improve performance, reduce downtime, and ensure compliance with current and upcoming Chrom(VI) regulations. If you are evaluating thermal spray as a replacement for hard chrome plating, our experts can support you with material selection, application insights, and coating solutions tailored to your requirements.

Contact our experts